1. David Stonecipher, Global Industry Director
Brian Everett, Creative Design Manager
Eduardo Alvarez, Industry Manager
Dave Persing, Industry Manager
February 2015
Unlock Luminaire Design and
Performance Possibilities
2. 1. The market challenge
2. Leading by design
3. Material selection considerations
4. Production scale-up demonstration & best practices
Agenda
February 2015 Page 2PolyOne Corporation
3. The Lighting Market Challenge
February 2015 PolyOne Corporation Page 3
Lighting Manufacturer
Technology Revolution Fickle Consumers
New Competitors Costs & Prices Dropping
4. How Will You Lower Costs?
• “The price premium
for LED lighting
continues to pose a
barrier to adoption
in many
applications.”
• LED lamp costs
expected to drop
55% and luminaire
costs to drop 30%
by 2017
February 2015 Page 4PolyOne Corporation
Source: US DOE October 2013 report entitled “SSL Pricing and Efficacy Trend Analysis for Utility Program Planning”
5. Materials & Manufacturing Represent
65-75% of Total Cost
0 20 40 60 80 100
Raw
Materials
Manufacturing
Logistics
SG&A
Profit
February 2015 PolyOne Corporation Page 5
Source: Internal PolyOne analysis
45% 28% 14% 7%6%
6. • You could understand what your customers really want and
build that into your designs?
• You could design a luminaire with processing and performance
in mind and get it right the first time?
• You could lower your cost per lumen while enhancing your
brand and market share?
February 2015 PolyOne Corporation Page 6
7. Polymers Have Unlocked Possibilities in
Other Industries
1965 Mustang
February 2015 PolyOne Corporation Page 7
2014 Mustang
8. Material
Selec+on
Produc+on
Design
Collaborate for Best Results
Successful polymer
component
February 2015 Page 8PolyOne Corporation
9. Design Philosophy
Have design involved early in your process
February 2015 PolyOne Corporation Page 9
Start
Finish
Define
Research
Conceptualize
Refine
Prototype
Implement
Material,
Process,
&
Supply
Chain
Exper+se
Speed
&
Reduced
Risks
10. Thermo formed
Acrylic diffuser panel
Injection molded cap
Extruded vinyl housing
Design Process
PolyOne Corporation Page 10
Understand your manufacturing options
• EVERY application has more than one solution
February 2015
11. Design for the “Future”
PolyOne Corporation Page 11
• Solve today’s problems but keep awareness on future needs
• Take advantage of emerging technologies
February 2015
13. Part Finish
PolyOne Corporation Page 13
Replicate natural materials with printed films for unique aesthetics
• Reduce manual labor costs and assembly times
February 2015
14. Part Finish
PolyOne Corporation Page 14
Use hydrographics in unique applications that were never before possible
February 2015
16. Material
Selec+on
Produc+on
Design
Collaborate for Best Results
• Performance
• Regulatory
• Innova+on
• Manufacturability
• Consistency
• Innova+on
• Property
profile
fit
• Availability
• Innova+on
Successful polymer
component
February 2015 Page 16PolyOne Corporation
17. Materials – Choosing Among Many Alternatives
February 2015 PolyOne Corporation Page 17
Housing
Heat Sink
Reflector
Lens
System thinking: Analyze the requirements for every subsystem and
their interactions with hardware and software
18. February 2015 Page 18PolyOne Corporation
Light Transmission:
Clear Diffusion
Flammability:
UL94-HB UL94-5VA
UV Performance:
Indoor UL746C f1
Impact:
> Glass Vandal proof
LED Luminaire Component: Lens
27. Industrial High Bay Case Study
February 2015 PolyOne Corporation Page 27
α
=
5
W/m²K
Aluminum
Thermal
Polymer
Same
Design
10
W/mK
Thermal
Polymer
Redesigned
Part
10
W/mK
Max
Temperature
52
63
53
°C
Min
Temperature
50
48
51
°C
Weight
11.6
lb
6.2
lb
2.0
lb
Redesign to optimize
28. Economic Impact
February 2015 PolyOne Corporation Page 28
From
18
lb
to
6
lb
/
luminaire
=
67%
weight
reduc+on
From
$73
to
$47
/
luminaire
=
36%
cost
reduc+on
29. Material
Selec+on
Produc+on
Design
Collaborate for Best Results
• Performance
• Regulatory
• Innova+on
• Manufacturability
• Consistency
• Innova+on
• Property
profile
fit
• Availability
• Innova+on
Successful polymer
component
February 2015 Page 29PolyOne Corporation
30. Metal to Polymer Conversion Demonstration
Design Goals:
• Convert off-the-shelf down-light
• Use only engineered polymers
• Measure lumen performance
• Demonstrate heat removal
• Estimate savings potential
February 2015 PolyOne Corporation Page 30
39. Polymer Conversion Results
February 2015 PolyOne Corporation Page 39
PARAMETER RESULT
Light
(lumens) Equivalent
Board
Temperature
(oF/oC) 127oF
(53oC)
…
146oF
(63oC)
Weight
(lb.) -‐54%
No.
of
Components
(#) -‐31%
Tooling
Life
(#
units)
10X
Component
Cost
Savings
(est.) 36%
savings
40. Polymer Conversion Best Practices
Design
• Create compelling look; NOT a drop-in replacement
• Simplify, consolidate, differentiate
Material Selection
• What are your performance needs?
• Consider regulatory requirements
Production
• Don’t let tooling be a hurdle
• Utilize latest computer prototyping tools
February 2015 PolyOne Corporation Page 40
Participate with someone who completely understands
polymer design and processing
41. Let Us Help You…
• Place your business card in the fishbowl
• Five drawn receive a free polymer conversion consultation
February 2015 PolyOne Corporation Page 41
42. David Stonecipher, Global Industry Director
david.stonecipher@polyone.com
440-930-3323
Brian Everett, Creative Design Manager
brian.everett@polyone.com
314-569-7432
Dave Persing, Industry Manager
david.persing@polyone.com
440-930-1958
Eduardo Alvarez, Industry Manager
eduardo.alvarez@polyone.com
203-239-9629 x2019
Questions?
http://www.polyone.com/files/resources//
Strategies_in_Light_2015_LED_presentation.pdf
